General process of bonding



Patented ct'. ,2, i934 UNITED; STATES PATENT OFFICE GENERAL raocnss or nonnm Willis A. Boughton, Cambridge, Mass, assignor to New England Mica 00., Waltham, Masa, a

corporation of Massachusetts No Drawing. Application June 22, 1931,

Serial No. 546,153 g g 20 Claims. (01. 154 2.5?

This invention relates to an improvement in the art of bonding, binding, or cementing non-reacting and non-dissolving surfaces, and thereby integrating separate fragments, pieces; particles,

I films, layers, threads andflbers, into what are.

substantially unitary bodies.

in the following description and. discussion of the several inventions disclosed herein, reference is made to its relation to the-manu- 10 facture of laminated and other mica and insulating products, however, it should be understood that the application of the properties, prin- I ciples, and methods disclosed hereinmay be made to other uses and materials, such as in the manuiacture of adhesives, molded articles, lute's, etc.,

and such applications are included asamong these inventions; other applications of the inventions'will be obvious to those skilled in. fields where the inventions may be applied. The description and claims herein are intended to include the above, and also other fields of usefulness without constant reference to them here in detail in view of my recognitionof the general broad value of the inventions; and of my understanding and application of the principles involved and because of the impracticability of listing all of such applications in detail in this specification,

An object of the invention is to provide an inorganic binder for a great varietyof products,

which shall be highly adhesive, and shall be substantially unaffected by organic liquids or vapors at any temperature; and shall be water soluble to promote easy removal when desired; non-charring, non-comhustiblefire-proofing; of low cost;

free from risks of a sanitary nature during manuiactureand use; of high dielectric strength, and capable of retaining these and other valuable properties at temperatures above those, at which the generally used bonding, materials if organic,

char or burn, and if inorganic, intumesce or decompose with the destruction of binding quality. A furtherobject relates to the preparation of inorganic lutes, and cements,-which shall be reversibly thermoplastic, soluble in water, and insoluble in organic liquids and vapors. A further object is the production of a variety of electrically insulating products which do not char or carbonize at elevated temperatures, and

that are of low cost;

Further objects of the invention will be apparthat may be producedin a variety of :shapes, and

out to 'those skilled in the various mechanical- .arts after reading the specification.

Heretofore, adhesives, binders, and bonding materials of thekinds which havebeen applied to many modern arts not of a ceramic nature have been composed exclusively of organic substances, as resins and gums. Because they are organic, such materials have a tem-.

perature range of usefulness. Their application often requires the employment of expensive bind-- ers, solvents, etc., and may constitute an actual hazard from fire, poisoning, etc.

For example the low temperature mica sheet of commerce heretofore ordinarily obtained 'is composed of pieces, films, flakes, etc., of split mica cemented together with an organic binder. such as a natural or synthetic resin, or a composition comprising a resinous or glue-like adhesive, Integration of suchfllms, flakes, etc., by such resin, is secured by rolling, pressing, etc., under a variety of conditions. Such a mica sheet is am, has a moderate to high dielectric strength, is capable in its several forms of being punched, molded, made flexible, made. rigid, etc. But such a micasheet has several obvious disadvantages as followszv-First, because of the organic nature of the binder it cannot resistthe action of heat above its char-ring point, and whensubjected to temperatures higher than, say, 200 C. it carbonizes, .de-laminates and disintegrates; or the binder may volatilize leaving the mica pieces .in non-adhesive contact. Under conditions of care.- less use or over-heating such an organic-bound .sheet gives off objectionable fumes, and may actually take fire, and thus constitute areal fire risk. Second, the binder, being organic deteriorates in the presence of oils, organic solvents, and similar corroding organic materials; sheets so bound suil'er slow or rapid def-lamination in contact with such organic materials. Third, organic-bound. laminated mica sheets usually if not invariably show a marked decrease in electrical puncture resistance with increase in tem-:

perature. Fourth, the more useful natural and synthetic resinsare expensive, and the cost of the sheet is correspondingly high. Fifth, the process of manufacture usually involves the use of an organic solvent in which the-binding resin is distributed to permit cementing one layer of mica pieces to another; and this solvent is an expense, as is its recovery for use again, and may also constitute a sanitary hazardin the factory.

These objections also apply in general to the use of organic binder and stifleners used for various other purposes. It has seemed highly desirahle, therefore, to replace such organic binders and bonding materials in part or in whole, with others that do not exhibit the disadvantages cited above. The search for satisfactory substitutes has, however, been hampered it not completely prevented by the stubborn belief, practically universally held, that inorganic materials are invariably crystalline or. earth-like; non-adhesive,

non-thermoplastic, and lack entirely the possibility of furnishing substances having properties suitable for adaptation to .the above mentioned processes and products- After considerable research with various inorsolution.

' ited degree; etc.

sodium metaphosphate',- NaPoa;

' as the chief solid constituents of a series of inorganic binders. and b0 ding materials, adhesives,

'thermo'plastics, etc., not only forlaminated and other mica products, but for molded compositions of various kinds, adhesives, stiffeners, thermoplastics, lutes, etc. These few inorganic materials play the same part in the inorganic binder as the resin constituents, for example, plays in the usual organic binder. The solvent, instead of being an organic liquid, is water or an aqueous inorganic such compounds as glacial phosphoric acid, HPO3; sodium monoborate, NaBoz; other alkali metaphosphates and m noborates such as the respective "ammonium, lithium, and potassium compounds; also a few other chemically related compounds; also a variety of salts of the element beryllium; sodium silicates to a lim- I'hese are all'characterlzed by These substances include the property of forming highlyviscous aqueous .pable of being made solutions in concentrations, in the neighborhood of fifty percent, the viscosity usually being greater than that of glycerine and often as great as that of asphalt, or practically solid, depending on the amount of water in colloidal association with the salt molecule. These substances hold tenaciously to their colloidally attached water, as described below, yielding it up only slowly at temperatures considerably above the normal-boiling point of a concentrated aqueous salt solution: Definite analyses are difiicult toobtain because of the abnormal physi'cal nature of -such substances, but -I have found that there is still residual water associated with them at temperatures upwards 'of 150" C. In general, the smaller amount of water associated'with such an anomalous inorganic substance, the higher its viscosity at ordinary temperatures. The facts 7 viscosity of aqueous associations of the substances specifled app ar tion of the known inorganic substances capable of .forming. viscous aqueous associations are also caadhesive and bonding, ob-' viously a totally different quality and not in any sense a necessarily inherent property of an inorganic viscous association with water. Thus as examples of non-adhesive viscous liquids I may cite concentrated having however no binding properties. Similarly 'a super-cooled supersaturated solution of calcium nitrate, or magnesium nitrate-is a viscous liquid (although this fact -is not recorded in chemical literature to, the best of my knowledge) but neither is-a bonding liquid as are the aqueous asthis invention. I desire-to clear between, the property associationand the exhisociations claimed in make the distinction of viscosity in aqueous .bition of bonding power, the latter not'beingnecform 'an ,aqueous solution-.01 the glassy hexabelow thelbolling point polymer at a temperature possible. The common of water and as rapidly as commercial powdered sodium 'metaphosphate cannot be so used until after fusion when it is transformed to the glassy hexasalt. Similarly manufacturing processes.

colloid-like in nature,

of the colloidality and in the chemical literature, but I have discovered that a small propor-' sulfuric acid and orthophos-' phoric acid, bothof which are markedly viscous,

' sure integration is attained, often at temperatures limcareful control of conditions and as such constitutes an invention.

To resume, in very definite ways the inorganic materials I have developed as described herein, have the properties and uses that have heretofore been associated solely with substances of organic nature, such as resins, oils; greases, adhesives, and other bonding materials. To the best of my knowledge these analogies of properties and uses have not previously been recognized andutilized,- and it has not been previously known that the inorganic substances herein described may replace the'above-mentioned organic materials in a. number of arts and processes withimprovement in the products especially with respectto increased'temperature ranges of usefulness, complete resistance to me, far less danger' to the health of workers employed in the various processes of manufacture because of elimination of poisonous organic binder materials and solvents, and greater cheapness. of

As indicated above these inorganic materials in general include those which may under suitable treatment or conditions form highly viscous aqueous solutions, or bodies, 'which are noncrystalline and bonding, and may be colloidal or or at least'resemble' organic colloids in many properties. They yield theirl water content with increasing slowness at temperatures well above the normal boiling points of most aqueous inorganic solutions. When subjected to further heat they continue to yield residual water with increasing difliculty, are'l usually highly viscous liquids, and even though some pass through a crystalline,.hard or dry stag'e, traces of water are retained up to fusing of the material, which frequently is above low red heat, In the viscously fluid substances have been found to'be binders for a variety of materials, and when the adhesion of binder and bonded surface is effected under presup to the fusion point of the anhydrous binder, and a product is obtained that retains its useful properties up to approximately the temperature of original manufacture.

soniay constitute binding-fluids at these respectlvehigher temperatures, yielding products of a controllable solidity at ordinary and elevated tem-- l peratures, up to the chosen temperature of fluidity of the binder. All of these non-crystalline and 'bonding inorganic bodies are reversiblythermo' plastic. A

'I wish to be clearly understood that I recognize, and make use. in this inventionof the principle stated in the Dawesj and Boughton patent, 1,578,812, coveringmica products, to the effect that certain inorganic substances. show the characterlstic of fluidly flowing at lower temperatures 1 state these T' materials used and the actual under high pressure than at ordinary pressurei however, the present invention is in part an improvement over the invention in the Patent 153M312, in that I utilize this principle in causing certain inorganic materials associated with appreciable amounts of water to flow under high pressure and bond associated surfaces together when atwordinary pressures no such' bonding could patent; temperature and non-hydrostatic pressure are "to be considered as interchangeable fac-- semhle each other closely in common ways, nor indeed in the herein described properties of high erlw of bonding. For example, an aqueous solulion of sodium metaphosphate is acidic, while that of sodium monoborate is alkaline. Sodium metaphosphate in the common commercial form of a white powder is practically insoluble in water.

- The solution I employ must be prepared under the stated condition from the fused sodium metaphosphate glass called Grahams salt, and when heated under certain conditions depolymerizes to insoluble, crystalline non-viscous and non-adhesive form; while sodium monoborate may crystallies at ordinary temperatiues when in concentrated solution. Inboth cases, however, crystalhe restrained by suitable means, for example, by the application of selective pressures, and the range of temperatures over which these substances function asvis'cous fluids is thus con-.

siderahly increased. Metaphosphoric acid HPO3, ordinarily shows no particular tendency tocrystalliae as the water of colloidality is driven off, but appears to pass smoothly from the viscous aqueous solution to the viscous molten glass which is subfree from meta-phosphoric acid is kept fused at high temperatm'e for :a pc odor hours it becomes almost in water. Other alkaline metal metaphosphates and monoborates may be made to .form similar highly viscous solutions, but each 4 has its own characteristics of temperature, cryspr amixture of salts, etc.,

herein cited or operates usefully over some par- 'ticular range of conditions.

- scopicity, etc.

a. etc.

talliza 'tion, electrical resistance when dry, hygro- .Also, beryllium sulfate, BeSO4, especially in the presence of a slight excess of 0xide or carbonate, can be treated in such a way as to fm1m a useful viscous solution of excellent properties of adhesion, electrical resistance when particular-field each acid, or salt, is useful for the purpose similarly. In its Suitable "combinations of such substances yield properties which in general are additive; as in the case of the analogous organic materials. Thus a viscous aqueous solution of sodium metaphosmonoborate,

phateTis abetter electrical conductor than one of and the conductivity of a he obtained because of the inhomogeneity of the Y binding material. As stated in the above cited of the nature cited here do not necessarily r etemperature of manufacture even viscosity and colloidality and the developed propadvantages cited above in colloidal water, yet when beryllium compounds act mixture of these two substances is substantially an average between the two individual conductivities.

Furthermore sodium metaphosphate in the crystalline form, when heated to still higher temperatures fuses again to forma viscous glassy liquid which is thepolymerized Graham's salt;

and at these temperatures it is again an adhesive for such substances as mica pieces.

These various collectiveand individual properties are fully taken advantage of in the severalapplications of my invention as described. By a suitable selection and combination of the simple chemical substances of the class described, with or without admixture'of other substances in minor amounts, it has been possible to prepare.

laminated mica sheets, for example, with varied properties, at will, to suit the special needs of industry and commerce, in great variety. These may be made to operate with high satisfaction in their respective fields up to temperatures considerably higher than the maximum tempera-' tures at, which the corresponding organicbound mica. sheets may be employed with safety and in a more limited way sheets can be prepared to operatesatisfactorily up to the approaches the decomposition temperature of mica itself. 7

As compared with organic-bound mica sheets, those made with my inorganic binders show extraordinary advantages. The process of manufacture itself is simpler, cheaper, and safer from the standpoint of sanitation and fire risk. Thus, the solid binder constituents are usually cheaper than the resins used fororganic-boumi plates. the actual manufacture of the inorganic plate is simpler, and the solvent is-inorganic, for example water, or an aqueous solution of an appropriate salt, instead 'of usually an inflammable and poi sonous' organic 'liquid. Into their manufacture, therefore, no such risks and hazards and discomforts enter as in the case of organic-bound mica sheet. The sheets formed are oil-insoluble, noncharring, non-burning, and, in the more highly dehydrated forms, of superior electrical resistance. It is obvious, of course, that the properties and the case of laminated products also apply to these viscous inorganic ma-' terials when used in other ways, for example, as cementitious materials to be used with various fillers for the preparation of plastics, for lubricants and lutes, for adhesives between surfaces other than mica, such as of cellulosic materials, textiles, metals, etc., for surfacing to withstand the action of organic vapors, liquids and solids, as forms of disinfectants in-the case of the metaborate mixtures, and for many other purposes that will-.be entirely obvious to those to whom the properties of these substances are familiar Typical formulas, compositions of matter, and

though that examples of use and application are as now add a slight excess of base. The 156 7 until at the higher. dehydration temperatures an lost. The temperature at which solution is concentrated by evaporation or is diluted, as may be necessary to produce a liquid that contains 30% is formed and the desirable partly or wholly intumescent solid condition of viscous liquidity is place appears lution may exist in mutual contact at temperaorganic-bound mica sheet of commerce.

tures ofv 110-125". Under pressure, however, the

viscous adhesive condition persists to temperatures above 200 C.

Such a viscous liquid may be variously employed. Inythe manufacture of flexible mica' sheet the. concentration of the solution used depends upon the conditions of manufacture and.

the temperature at which useful -fiexibility is desired; and also upon the percentage of binder which the sheet is-to possess. Thus for a sheet of useful flexibility at ordinary temperatures and of binder content less 25-30% concentration may be employed. This solution The sheet is then transferred to ahot table where it is rolled to eifect thorough cementation of the pieces, to remove excess of binder and to dehydrate the liquid to the viscosity at which correct flexibility of the sheet is attained.

For storage, such' a flexible sheet may be protected against further spontaneous dehydration and consequentloss of flcxibilityby coating with a drysealmg composition, or by wrapping in waxed paper or other water-non-penetrating tissue. or in anyothe'r customary manner.

Such a sheet has all of the non-resilient flexibility of the highest quality of organic-bound flexible sheetl In addition it is not disintegrated by contact with oilsand greases, a common fault with organic bound sheet; it does not char, burn, or give 61f fumes when subjected to higher temperatures. Its dielectric strength is 300-400 volts per mil, and this value riseswhen the sheet is dried out by heating, reaching values above 600 volts per mil, whereas organic-bound sheetsu'ffers'a gradual. loss inelectrical resistance when subject to elevated temperatures, (above about dehydrates and mayeventually -ify, showing then, howeve'r, anAincrease-in electrical. resistance and a'restraint of intumescence.

At temperatures upwards of 110 c. the binder of the sheet in flexible form, if under even compression as in a manufactured article, further somewhat opac- When subjectedto overheating suificient to destroy an'organic-bound plate,'this will, .under suitable conditions only improve the electrical resistance of the inorganic bound sheet.

, To produce a mica sheet to be' flexible at, say,

100 'C.,' it is only necesary to further-the" dehydration of the common flexiblelmica sheet. I C.) or only l other respects its properties are those described Such a sheet (flexible at 1005 slightly flexible-at ordinary temperatures.

above. When such flexible sheet is heated=to 200"'-'C., for example; crystallization and intumesccnce would normally-takeplace; however,

, under .eifective pressures. from .moderate ,pres-- sures to upwards of 100-200 pounds'per square inch. crystallization and intumescence are avoidthis change takes to vary with the pressure. Whenuncompressed, intumescent solid and .viscous 50- than 20%, a solution ofis applied as in the-manufacture of the forming an acid solution which strength is in the vicinity 'low value, but when the-flexible sheet'is dehyjpolymerization takes place,

the sheet is highly At still higher of manufacture,

sheets are formed'that will retain the admirableproperties cited above under. conditions of rising temperature up'to approximately the temperature of manufacture, or that of the complete dehydration of the binder compound.

Such a binder may obviously tic, constituting the binding luting, or lubricating. composition containing a powdered or fibrous filler such as talc, lithopone,

graphite, or powder ofsimilar non-reacting kind,

or asbestos, or cellulosic fiber,etc. When heated under pressure with loss of solvent such a mass furnishes a moldable product adapted to many needs;

Other uses andapplications will be entirely apparent to those familiar with the various arts.

(2) Sodium metcphosphate This substance formerly a chemical'curiosity is 'now an article of commerce. Itis known to exist inseveral polymerized forms. For the purposes herein cited I use the form called Grahams salt oohexa'metaphosphate, of the reputed formula (NaPOz) 5, althoughl may effect transformation of thisform to yield one or more other formsf Grahams salt is a glass which is soluble in water, may be prepared in desired concentrations by powdering the glass andmixing the powder rapidly with the correct amount of, water, or preferably by placing the glass in a. vessel containing less water than required, eifectin'g rapid solution violent agitation, and diluting the resulting liquid with more water until the desired concentration such high pressure 800 volts per mil,

be used as a plasfactor of a plastic,

by warming and,

is reached.- Such a highly concentrated solution has apparently not been known by others because the usual way of increasing concentration, name- -ly, by application of heat, results in depolymerization and crystallization of tlie solution. For making mica sheets the concentration may be 15% or less. For lubrication, making molded products, lutcs, etc. the concentration :may be greater than 60%.

The diiferences in viscosities between various concentrations of such compounds is striking. The 15% solution is less viscous than glycerine, while the 60% solution is as viscous as a-heavy; slow flowingtar. Solutions of ammonium meta-- phosphate'or'metaphosphoric acid may be pre-' pared which are so viscous as to be essentially" solid at" ordinary temperatures. When an aqueous solution of sodium metaphosphate is boiled it becomes more concentrated and the boiling temperature rises; at 110-130 C., depolymerization partly or wholly takes place and fine, white, water-insoluble crystals appear in the viscous liquid,'or-the entire liquid becomes crystallized and solidifies to a I cake. In the manufacture of mica sheet and other products-I take advantage of this-peculiar, property as follows:-Tlie sheet'is prepared in flexible formas described above. "As such the dielectric of 100:volts per -mil; a

dratedby heat-(at about 110 C. to 0.) dethe sheet opacifies and hardens by crystal formation and electric strength rises to about ,400 volts per mil.

without completely losing its firmness.

The sheet thus formed is hard and non-flexible As the temperature is further increased the electrical resistance rises slowly and the sheet retains its rigidity to a temperature of 400 C. or so when residual water is given off, the crystals sinter, andin the neighborhood of 500 C.-, fuse to form a viscous adhesive fluid of substantially anhydrous sodium metaphosphate that again furnishes a binder for mica films, but in this stage, with good electrical resistance continuing as such up to the decomposition temperature of mica itself.

Tubes of practically any desired diameter and wall thickness may be prepared by rolling the low temperature flexible mica sheet, bound with this or other inorganic binder, or mixtures of such binders, cementing the layers together with more binder. These show the expected properties of hardening at temperatures above about 110 C.,

and then becoming electrical insulators with superior properties, remaining useful as supports forresistance wire and ribbon, and for other purposes up to high temperatures as described above. Such tubes may be heated above the fusion point of the binder whereupon they acquire the improvement in electrical and physical properties indicated above when the binder is fused. a

The crystallization and hardening of the sodium metaphosphate takes place even under pressure,

.unless restrained by suitable means;

. (see .my application entitled Method of restraining crystallization, filed June 22, 1931, Serial Number Sodium metaphosphate in admixture with cer- -tain other materials, as described separately,

yields binders, lubricants, etc., 'that crystallize at much higher temperatures than is the case with the single substance, or remaincontinuously fluid up to the temperature of anhydrous fusion, yielding solid integrated products at respectively lower temperatures. In preparing such a mixed binder I may first dissolve thesodium metaphosphate as described and then add the other constituents orobviously I may prepare an aqueous solution of the other constituents and dissolve the sodium metaphosphate init. Laminated mica sheets made with such binders when heated to temperature upwards of 300 C. or under pres-' sures of -200 pounds per square inch retain their 'clearness and are superior in physical properties to the best organic-bound sheets.v They have the enormous additional advantages of showing no electrical breakdown at temperatures up to approximately the decomposition tempera.- ture. of mica itself, and of course they do not char, smoke, or fume as do organic-bound sheets.

or de-laminate at the same comparatively low temperature.

Howeve it must be noted that such 'an inorganic-bound sheet may under certain conditions, crystallize at some temperature above that of manufacture. Nevertheless, it is a general and broad rule that sheets may be prepared from selected formulas, at higher temperatures and pressures, that retain-their 'clearness, integration and freedom from crystallization up to their respective temperatures of manufacture; even to ap-1 proximately the decomposition temperature of mica itself. A fewsuch formulas comprising sodium metaphosphate as the chief constituent, are as follows. The proportions given are parts of dry material by .weight:

' (a) Sodium metaphosphate 20, sodium carbon ate 8, potassium thiocyanate 2, secondary amaomova form the metaphosphate. -Mixture water underneath escapes monium phosphate 2, sodium tungstate 2, am-

- monium molybdate 2. The mixture when applied as a solution to mica pieces as usual gives a clear colorless mica sheet of excellent adhesion and other physical properties, and when pressed at 180 C. loses a part of its water without crystallization, intumescence or opacification, and has then a dielectric strength of about 1000 voltsper' mil.

(b) Sodium metaphosphate '20, potassium carbonate 2.6. ammonium metaphosphate 2. Under the same conditions of manufacture as (a) this yields a mica sheet of equally superior properties and a dielectric strength of more than 900 volts per mil.

(c) Sodium metaphosphate .20, potassium dichromate-2. This formula yields a plate of excellent physical qualities and a dielectric strermth of 500-600 volts per mil.

Mixtures of two or more alkali metal metaphosphates furnish similar superior compositions.

The neutralization of the natural acidity ofa so-' lution of sodium metaphosphate with other alkali metal carbonates yield. such mixtures. They may also'be formed by addition of therespective metaphosphates formed by neutralization of meta: phosphoric acid solution with the respective carbonates or hydroxides, and in the case of am A.

monium metaphosphate by addition of any of the orthophosphates, the latter salts readily decomposing at comparatively low temperatures to (b) cited above is'essentially a'mixture of sodium, potassium, and ammonium metaphosphates, when the application of heat and pressure is completed.

It will at once be apparent that the various specific or developed properties of sodium metaphosphate both alone and in admixture with other salts may be appliedto other uses than the manufacture of mica sheet and tube. I have discovered, for example, that the viscous solution when freely exposed to-the air loses surface water with the formation of a dry film through which the slowly, but eventually such a solution dries at ordinary temperatures to ahard, tough horny and glasslike mass. .11; is an excellent adhesive for a variety of materials. It is obviously of great value as a plastic base in the manufacture of molded products. other uses will also be apparent at once;

(3) Sodium numoborate The aqueous solutions of this material show high viscosities, especially in ,the ranges of concentration above 35%, although for any concen- 130 tration the viscosity of themonoborate solution is lower than that of the metaphosphate;

Nevertheless, these solutions when prepared under the conditions I employ can be made to show extraordinary bondingstrength in thin lay- 18$ 4 ers.

der ordinary pressures and at temperatures of about C. to C. solutions of sodium monoborate tend to vdry out and intumesce very much as does crystallized borax. At higher pressures, upwards of 100 pounds to the square'inch, ever, viscoslty'is usually retained at temperatures higher than 180'C., especially when small quantitles of crystallization restraining salts are prescut. .The electrical resistance in all stages is usually greater than thatof sodium metaphos- Various The properties of commercial samples vary considerably in detail but all such samples tend to crystallize on standing atordinary temperatures unless this is restrained by suitable means. 1111- howphate.

' quality,

2, ammonium phosphate-1.-

- ertie s.

about 700 volts permil.

'tion when heated above Thus in flexible form the dielectric strength of a monoborate bound sheet may run between 200 and 300 volts per mil. When the sheet is rolled at C. the dielectric strength increases to more than 700 volts-per mil; and

when pressed-at 180,-C. dielectric strengths of approximately 1200 volts per mil have been customarily obtained. The mechanical and other properties of the sheets equal to those of the best metaphosphate boundsheets and superior to those of organicbound sheets.

When a monoborate bound sheet is heated in the open, above the temperature of its manufac ture under pressure, the binder intends to ill-- tumesce and the sheet to de-laminate with consequent loss of many of its useful properties. As

in the case of sodium metaphosphate the range of temperature over which the useful condition of transparent or translucent viscosity and developed binding property persists ma however, increased by admixture with certain otherkinds of inorganic substances as described elsewhere.

' Thus, the following mixtures comprising chiefly sodium monoborate have shown prop'erties superior to those of thissubstance alone:-

1Sodium monoborate 10,ammoniumiodide 1.

. 2 Sodium m0noborate -10, sodium pyrophos-- phate 1.

3-Sodium monoborate 10, ammonium nitrate-1. 4$odium monoborate 8, potassium phosphate In other respects and in its various treatments I and uses such as herein described are concerned,

sodium monoborate resembles sodium metaphos- Admixture of other monoborates should be done by preparation of the several monoborates sepa- 'rately, rather than by addition of carbonates,

since sodium monoborate solution, is alkaline.

' Such admixtures show an. elevation of crystallization temperature analogous to that observed with the metaphosphates.

Mixtures containing only metaphosphates and monoborates. Essentially neutral phosphate, sodium mixtures of sodium meta monoborate and phosphoric acid furnish binding mixtures of excellent prop- One such mixture containing sodiummeta'phosphate 6,.sodium monoborate5, metaphosphoric acid 1, gave a dielectric strength of (4) Alkali meta lsilicates It has-long been known that the sddium silicate solution of commerce is a binder of excellent properties. .Various attempts have been made to utilize its adhesiveness in the manufacture of laminated mica products, but-these have failed because of the intumescence sufl'ered by this soluabout 90 C.-, as well as the corrosion induced by its highly alkaline nature. As a result sodium silicate hasfallen into disrepute as a mica binder, and no product will ordinarily flnd a sale which is known to contain "silicate" in its composition. However, when alkali metal 'silicates are .treated as described above it is quite possible to use them as general bonding materials under conditions herein stated and make products that are satisfactory, al-

though perhaps not equal in all respects to those described above.

. Under temperatures and pressures as described above under (1), 2), and (3), intumesoence and crystallization are restrained and sheets of fair so obtained are of a high' solids, for example, asbestos fibers, powdered' ftaining an alkali metal metaphosphate and at This happens because the association of silicate molecule with residual water functions as a .viscous liquid. under such pressures and intumescence is overcome yielding a clear binding fluid at the temperature and pressure of operation.

Molded products shaped into'a variety of forms may be madeby mixing fragments of selected mineral matter, etc.,-with desiredquantities of any of the above cited bonding inorganic substances-or mixtures thereof described herein, heating and pressing, and molding to the desired configuration, and allowing to cool. Such products are stiff and rigid, are not aflected by the usual 7 changes of -weather and temperature; do not char orburn. and may be mechanically worked. As a luting or cementing agent, the new com-- positions described herein have a wide field of application. Theyare all reversibly thermoplastic. Joints between two articles may be made by warming the substancesto be joined, applying any of the viscous non-crystalline and bonding adhesive compositions or mixtures thereof, and where practicable, pressure may be applied; after cooling,:the joint will be'tight, resistant to all organic solvents and vapors, and-will not char or burn'bythe application of heat. 1 It is'apparent therefore, that recognition and utilization of the property of forming adhesive viscous aqueous solutions and compositions, and which upon concentration are non-crystalline, and

which are capable of being developed into bonding 119 compositions under a variety of conditions, and the discovery of the method of bringing about bonding and of increasing the useful ranges of 1 temperature of the desirable properties. as revealed herein, constitute an invention which is new, of a fundamental and basic nature, and of marked value in the several arts and industries.

1. A laminated mica product, the flakes "of which are bound. with a viscous substantially non-crystalline and inorganic body containing a metaphosphate colloidally associated with sufficient quantities of water to retain reversible thermoplasticity in the product at temperatures inthe range of that of manufacture.

2. A laminated which a mica product, the flakes of e bound with a viscous substantially non-crystalline and bonding inorganic body containing an alkali metal metaphosphate colloidally associated with sumcient quantifies of water to retain reversible thermoplasticity in the prodnot at temperatures in the range of that of manx uIactm-e.

3. A laminated mica product, the flakes of which ane'bound with. a viscous substantially non-crystalline and bonding inorganic body con-' .taining a metaphosphate and at least one other non-precipitating inorganic substance colloidally associated with suiiicient quantities of water to retain reversible thermoplasticity in the product attemperatures in the range 'of that of manufacture.

. 4. A laminated mica product, the flakes of which are bound with a viscous non-crystalline and bonding inorganic body con,-

least one other non-precipitating organic substance colloidally associated with suflicient quantities of water to retain reversible thermoplastieity in the product at temperatures in the range of that of manufacture. 5. A laminated mica. product, the flakes of which are bound with a viscous substantially non-crystalline and bonding inorganic body con-,

taining a monoborate colloidally associated with sufiicient quantities of water thermoplasticity in the product at temperatures in the range of that of manufacture.

6. A laminated mica. product, the flakes of which are bound with a viscous substantially non-crystalline and bonding inorganic body containing an alkali metal monoborate colloidally associated with sufiicient quantities of water to retain reversible thermoplasticity in the product at temperatures in the range of that ofmanufacture.

. 7. A laminated mica-product, the flakes of which are bound with. a visco'ussubstantially non-crystalline and bondinginorganic body containing an alkali-metal monoborate and at least one other non-precipitating inorganic substance colloidally associated with suflicient quantities of water to retain reversible thermoplasticity in the product at temperatures in the range of that of manufacture.

- suflicient quantities of water to retain reversible crystalline and.

ing beryllium sulphate'colloidally associated with- 8. A laminated mica product," the flakes of which are bound-with a viscous substantially non-crystalline and bonding inorganic body containing a beryllium salt colloidally associated with thermoplasticity in the product at temperatures in the range of that of manufacture;

9. A laminated mica product, the flakes of which are bound with a viscous substantally non-,

bonding inorganic body containsuflicient quantities of water to retain reversible jthermoplasticity in the product .at temperatures,

: sired shape.

inthe range of that of manufacture. v

10. ,A laminated. mica product, the flakes of which are bound with a viscous substantially noncrystalline and bonding inorganic body containing a beryllium salt and at least one other nonsubstance colloidally asquantities of water to reprecipitating inorganic sociated with suflicient tain reversible thermoplasticity in the product at temperatures in the range of that of manuface ture..

11. The. method of making molded products from a mass of discrete particles which comprises mixing with said particles controlled quantities of a viscous adhesive inorganic body selected from a group consisting of the aqueous viscous solutioncompounds of metaphosphoric acid, monoborates;

and beryllium sulphate, and thereafter subjecting the .mass of treated particles to controlled heat from about C. upwards and an effective pressure from moderate pressure to upwards of 200 pounds per square inch to controllably reduce'the amount of water to retain reversible thermoplasticity in the product at temperatures in the range of that of manufacture and firmly bindsaid mass of particles into a molded body of de- 12-. The method of making built-up mica products from mica films which comprises applying to said films controlled quantities of a viscous adhesive inorganic body selected from agroup consisting of the aqueousviscous soiution compounds of metaphosphoric acid, monoborates, and beryl-. lium sulphate, adding further quantities of adhesive and films. and thereafter subjecting the mass of treated particles to controlled heat from about 100 C. to upwards of 500 C. and an effecto retain reversible duce the amount of water to retain reversible thermoplasticity inthe productv at temperatures in the range of that of manufacture and firmly bind the mica films into a mica product.

13. The method of making. built-up mica products from mica films which comprises applying to said films controlled quantities of a viscous adhesive inorganic body consisting of a substantially non-crystalline bonding colloidal association of water and a non-precipitating. alkali met- I al metaphosphate adding further adhesive and films, and thereafter subjecting the mass of treated particles to controlled heat from about 100 C. to upwards of 500 C. andan eifective pressure from moderate pressure to upwards of 200 pounds per square inch to controllably reduce the amount of water toretain reversible thermoplasticity in the product at temperatures in the range of that 'of manufacture and firmly bind the mica films into a mica product.

14. The method of making built-up mica. prod-e ucts from mica films which comprises applying to said films controlled quantities of a viscous ad-" hesive inorganic body consisting of a 'substantial-' ly non-crystalline bonding colloidal association of water and a non-precipitating alkali metal meta phosphate'and at least one other hon-precipitate forming inorganic substance, adding further. quantities of adhesive and films; 'and thereafter subjecting the mass of. treated particles to controlled heat from about 100 C. to upwards of 500 C. and an effective pressure from moderate pressure to upwards of 200 pounds per square inch to controllably reduce the amount of water to retain reversible peratures in the range of that of manufacture and firmly bind product. j V 4 15. The method of making built up mica products from mica films which comprises applying the mica films into a mica 115 quantities of.

thermoplasticity in the product at temto said films controlled quantiticsof a viscous adhesive inorganicbody consisting ofa substantion' of water and a non-precipitating alkali metal monoborate, adding further quantities of adhesive and films, and thereafter subjecting the mass of treated particlesto controlled heat from of 200 pounds per square inch to controllablyreduce the amount of water to retain reversible thermoplasticity in .the product at temperatures in the range-of that of manufacture and firmly bind the mica films mto-a mica product. I

16. The method of making built-up mica. products from mica films which comprises applying to said films controlled quantities of a. viscous adhesive inorganic body consisting of a substantially.non-crystal1ine bonding colloidal associationof water and a non-precipitating alkali met"- -al monoborate and at least one other non-precipitate forming inorganic substance; adding further quantities of adhesive and films, and thereafter subjecting the mass of treated particles to'-' controlled head from about 100 C. toupwards ofv 500 C. and an effective pressurefrom' moderate pressure to upwards of 200 pounds persquare inch to controllably reduce the amount of water to retain reversible thermoplasticity in the product at temperatures in the range of that of man-' ufa'cture and firmly bind the mica films into a mica product.

1'7. The method of making built-up mica'prodits tially non-crystalline bonding colloidal vassocia- 1 I to said films controlled hesive inorganic body consisting of a substantial and thereafter subjecting the mass of treated particles to controlled heat from about 100 C..

ucts frommica films V quantities of a viscous adly non-crystalline bonding colloidal association of water and a non-precipitating beryllium salt, adding further quantities of adhesive and films,

to upwards of 500 C. and' an effective pressure from moderate pressure to upwards of 200 pounds per square inch to controllably reduce the amount.

' 4 of water to retain reversible thermoplasticity in to said films controlled jecting the mass the product at temperatures in the range of that of manufacture and firmly bind the mica films into'a mica product.

1 8. The method of making built-up mica prodtucts from mica films which comprisesapplying quantities of a 'viscous adhesive inorganic body consisting of a substan- "tially non-crystalline bonding colloidal association of water and a non-precipitating beryllium salt, and at least one other non-precipitate forming inorganic compound, addinglfurther quantities of adhesive and films, and thereafter sub: of treated particles to controlled heat from about C. to upwards of 500" '0.

mrus A. noucnrou It is hereby-certified that error appeara which comprises app and an efl'ective pressure from moderate pressure to upwards of 200 pounds per square inch'to controllably reduce. the amount of water to retain reversible thermoplasticity in the product at temperatures in the range of thatol' manufacture and firmly bind the mica films into a mica product.

19. A laminated mica product,,the flakes of p which are bound by at least one inorganic adhesive substance selected from a group consisting of the aqueous viscous solution compounds of metaphosphoric acid, monoborates, and beryllium sulphate, said adhesive mass containing suflicient" quantities of water to retain reversible thermoplasticity in the product attemperatures in the range of that of manufacture;

20. A laminated mica product, the ,fiakes of which are bound by at least one inorganic adhesive substance selected, from a group consisting of the aqueous 'viscous solution compounds of metaphosphoric acid, monoborates', and beryllium sulphates, said adhesive mass associated with a crystallization restra compound, and containing suflicient quantities of water to retain re-' versible thermoplasticity in the product at temperatures in the range of that of manufacture.

I00 A. nooqri'ron.

cenrmcarz or com recount October 2, 1934."

in the printed apeeitication of the above numbered-patent requiring correction aafollows: Page 8, line 17, claim 18, for the syllable read sulphate;

tiona Office.

'- (Seal) Signed and aealed um 5m ill! a February," A. n; 1935.

"tucts" read ducts; and line 96, claim 20,- for "aulphates" and that the said'ILetters Patent should be read with these correcthercin that the name may conform to the record of the case in the Patent %9 t me; Acting Conin iaaioncr of Patenta.

' to said films controlled hesive inorganic body consisting of a substantial and thereafter subjecting the mass of treated particles to controlled heat from about 100 C..

ucts frommica films V quantities of a viscous adly non-crystalline bonding colloidal association of water and a non-precipitating beryllium salt, adding further quantities of adhesive and films,

to upwards of 500 C. and' an effective pressure from moderate pressure to upwards of 200 pounds per square inch to controllably reduce the amount.

' 4 of water to retain reversible thermoplasticity in to said films controlled jecting the mass the product at temperatures in the range of that of manufacture and firmly bind the mica films into'a mica product.

1 8. The method of making built-up mica prodtucts from mica films which comprisesapplying quantities of a 'viscous adhesive inorganic body consisting of a substan- "tially non-crystalline bonding colloidal association of water and a non-precipitating beryllium salt, and at least one other non-precipitate forming inorganic compound, addinglfurther quantities of adhesive and films, and thereafter sub: of treated particles to controlled heat from about C. to upwards of 500" '0.

mrus A. noucnrou It is hereby-certified that error appeara which comprises app and an efl'ective pressure from moderate pressure to upwards of 200 pounds per square inch'to controllably reduce. the amount of water to retain reversible thermoplasticity in the product at temperatures in the range of thatol' manufacture and firmly bind the mica films into a mica product.

19. A laminated mica product,,the flakes of p which are bound by at least one inorganic adhesive substance selected from a group consisting of the aqueous viscous solution compounds of metaphosphoric acid, monoborates, and beryllium sulphate, said adhesive mass containing suflicient" quantities of water to retain reversible thermoplasticity in the product attemperatures in the range of that of manufacture;

20. A laminated mica product, the ,fiakes of which are bound by at least one inorganic adhesive substance selected, from a group consisting of the aqueous 'viscous solution compounds of metaphosphoric acid, monoborates', and beryllium sulphates, said adhesive mass associated with a crystallization restra compound, and containing suflicient quantities of water to retain re-' versible thermoplasticity in the product at temperatures in the range of that of manufacture.

I00 A. nooqri'ron.

cenrmcarz or com recount October 2, 1934."

in the printed apeeitication of the above numbered-patent requiring correction aafollows: Page 8, line 17, claim 18, for the syllable read sulphate;

tiona Office.

'- (Seal) Signed and aealed um 5m ill! a February," A. n; 1935.

"tucts" read ducts; and line 96, claim 20,- for "aulphates" and that the said'ILetters Patent should be read with these correcthercin that the name may conform to the record of the case in the Patent %9 t me; Acting Conin iaaioncr of Patenta. 

